Large Arc when hooking up Negative Cable

[1laptech]

Hello,
Just picked up a 1999 Club Car DS series. It has been sitting for several years under a cover in the desert. I replaced all the the batteries and cables. Checked and rechecked all the cables to the batteries and accessories. The cart has an upgraded 5 HP electric motor and a flight systems upgraded 400 amp controller. Placed all the cables on the batteries (took pictures prior to removal) I went to place the Negative cable onto the post it was a large arc (noise and all), not a regular spark. Saw residue of metal from the cable on the post.

Possibilities??
Solenoid stuck open?
Bad controller?
Frozen / bad motor (Cart rolls)?

Any help
Thanks Tom

[NismoGriff]

Is there a Regen diode installed? Is it installed properly?

[Fairtax4me]

There's no Regen diode on a series cart. Might have a resistor on the solenoid large posts, but that will not cause arcing on the battery posts.

Double check that all of your batteries are installed correctly. Wired - to +. Also for now remove all other wiring from the pack (small wires for lights or other accessories). The only wires connected to the pack should be the main cables.

Make sure there is no damage to the main cables going from pack to motor to FnR switch to controller etc. If it sat for a long time look every cable over very carefully and make sure there's no rodent damage to any of them.

[ncfenceguy]

It's probably not this but I thought I would mention it. If the cart has a voltage reducer on it for lights and accessories, they almost always give off a pretty good arch (and pop) as the last connection is being made. It still makes me jump a little and I've put in probably 50

[NismoGriff]

Originally Posted by Fairtax4me

There's no Regen diode on a series cart. Might have a resistor on the solenoid large posts, but that will not cause arcing on the battery posts.

Double check that all of your batteries are installed correctly. Wired - to +. Also for now remove all other wiring from the pack (small wires for lights or other accessories). The only wires connected to the pack should be the main cables.

Make sure there is no damage to the main cables going from pack to motor to FnR switch to controller etc. If it sat for a long time look every cable over very carefully and make sure there's no rodent damage to any of them.

Ooops, I missed that he stated it was a series unit

[Sergio]

Originally Posted by ncfenceguy

It's probably not this but I thought I would mention it. If the cart has a voltage reducer on it for lights and accessories, they almost always give off a pretty good arch (and pop) as the last connection is being made. It still makes me jump a little and I've put in probably 50

I did get a surprise as well the first time I connected my cable after I installed a voltage reducer.

I now use an incandescent light bulb (or a old pre-charge resistor) between the cable and the battery post for a few seconds to allow the converter filter capacitors to charge before connecting the cable directly to the battery post.

[NismoGriff]

Originally Posted by Sergio

I did get a surprise as well the first time I connected my cable after I installed a voltage reducer.

I now use an incandescent light bulb (or a old pre-charge resistor) between the cable and the battery post for a few seconds to allow the converter filter capacitors to charge before connecting the cable directly to the battery post.

Yes, this suprised me as well, I called the guy I purchased it from to ask if it was normal. I like the light bulb idea!

[StumpNocker]

Originally Posted by Sergio

I did get a surprise as well the first time I connected my cable after I installed a voltage reducer.



I now use an incandescent light bulb (or a old pre-charge resistor) between the cable and the battery post for a few seconds to allow the converter filter capacitors to charge before connecting the cable directly to the battery post.

What a bright idea[emoji362]

Ok, ok, I'll stop lol

[_ogre]

it was brilliant!

[Fairtax4me]

Originally Posted by StumpNocker

What a bright idea[emoji362]

Ok, ok, I'll stop lol

Shocking!